ML20213G079
| ML20213G079 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 04/24/1987 |
| From: | Miller L, Willett D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML20213G063 | List: |
| References | |
| 50-312-87-14, NUDOCS 8705180113 | |
| Download: ML20213G079 (7) | |
See also: IR 05000312/1987014
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U. S. NUCLEAR REGULATORY C0fSISSION
REGION V
Report No.
50-312/87-14
Docket No.
50-312
License No.
Licensee:
Sacramento Municipal Utility District
P.-0. Box 15830
Sacramento, California 95813
Facility Name: Sacramento Municipal Utility District (SMUD)
Inspection Conducted:
March 23, 1987 to April 3, 1987
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Inspected by:
g hfl ett, R f
r Inspector
Date Signed
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Approved by:
LWlrer, Chief. Project Section 2
Date Signed
Summary:
Inspection on March 23, 1987 to April 3, 1987 (Report No. 50-312/87-14)
Areas Inspected: Routine announced inspection by a region based inspector of
licensee action on previously identified follow-up items and review of the
control room emergency ventilation system.
Inspection procedures 30703,
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92700, 92701, and 92702 were covered during this inspection.
Results:
In the two areas inspected, one violation of an NRC requirement to-
repair nonconformances in accordance with documented procedures and one
deviation from a licensee commitment to Regulatory Guide 1.52, which prohibits
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the use of silicone sealants to the essential air filtration system were
identified (paragraph 3.D and 4 respectively).
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8705180113 870429
ADOCK 05000312
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DETAILS
'1.
Personnel Contacted
- W. Bibb, Restart Implementation Manager
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- B. Croley,' Plant Manager
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- B. Day, Deputy Plant Manager
.*S. Knight, QA Manager
D. Army, Nuclear Maintenance Manager
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- R. Ashley, Licensing Manager.
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- R. Little, Licensing Supervisor
- T. Shewski, Quality Engineer-
- T. Martin; HVAC Engineer
- J. Janus, HVAC Engineer-
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- G. Blackburn, SRTP Engineer
- J. Robertson. Nuclear Licensing Engineer
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J. Field, SRTP Director
R. Colombo, Supervisor Regulatory Compliance
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- B. Kumar.. Environmental Qualification Engineer
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'R. Wise, Electrical Engineer
-W. Fargo, Electrical Engineer
C. Stephenson, Regulatory Compliance
D. Johnson, TMI~ Coordinator-
R. Thomas, HVAC Engineer
'G. Clefton,' Maintenance Supe'rvisor
lL.'Beltracchi,-NRR SPDS examiner
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- * Attended-the exit meetings.
The ~ inspector also held discussions with other licensee.and contract
personnel during the inspection. This included plant staff engineers,
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-technicians, administrative and clerical assistants.
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2.
Licensee Action on Previous Enforcement Matters
A.
-(Closed) Violation 84-19-03, Code Safety Testing
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In the original inspection report this item was incorrectly
identified as 84-19-01. This issue concerned a pressurizer code
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safety. valve which lifted at too low a pressure. This-valve was-
determined to have been incorrectly calibrated by the licensee, in
that a. maintenance calibration procedure to thermally stabilize the
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valve had not been followed.
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The-licensee replaced this valve, PSV-21507 (serial # BR 09499),
with a spare (serial # BM 09648), on January 17, 1985. The
licensee's response to the-Notice of Violation stated that: "This
' valve which had failed, would be removed and examined during the
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next refueling outage" (this refers to the March-June 1985 outage).
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The inspector reviewed the licensee's files to verify this
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commitment. This valve (BR 09499) was to be reworked via
Maintenance Work Request (MWR) 96496 issued 3-18-85. This MWR was
voided because it was a duplicate of MWR 96522. This MWR was also
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voided and MWR 115414 was issued June 10, 1986, so that the work
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would document the valve as found condition. This valve was
determined to'have excessive seat leakage. This work was completed
February 6, 1987,-and this valve was put in spare status.
Valve BM 09648 was also tested, on 12-16-86, and failed once at 2800
psig and twice at 2460 psig. Subsequent testing identified
. excessive seat leakage, which was repaired and returned to service.
This item is closed.
B.
(Closed) Violation 86-07-05, CR HVAC Excessive Flow
This violation (issued in report 50-312/87-01) concerned an
excessive air flow condition in the Emergency Ventilation System.
This condition was identified by the licensee during surveillance
testing, but the licensee failed to take take appropriate
corrective action.
The inspector reviewed the licensee's response to the Notice of
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Violation, which concluded that, based on the excess flow rate, the
total dose to personnel would not have exceeded design base limits.
These calculations are expected to be reviewed in a subsequent
uspection. The licensee has instituted the following additional
corrective action: The system engineer now reviews the results of
all surveillances, a surveillance procedure results review ~ guide is
being written, and training for personnel reviewing surveillance
tests'is to be provided. Based on the licensee's response to the
Notice of Violation, this item is closed. Open item RY-0-13
remains open pending a flow / dose. calculation review.
3.
Licensee Action on Inspector Identified Items
A.
(Closed) Follow-up Item 84-19-10, Turbine Bypass Valve Malfunction
This item was in regard to a turbine bypass valve (TBV), which stuck
open causing an overcooling condition. The adequacy of the
licensee's program to determine the cause of the failure was
questioned by the origional inspection report.
The licensee has manually stroked the valve and electrically tested
and cycled the valve. This valve has operated successfully several
times since this occurrence.
Subsequent inspections have identified to the licensee, the
importance of a deliberate and thorough trouble-shooting program to
evaluate system and/or equipment problems.
The licensee has committed (in report 50-312/86-30, item 01) to
develop a routine trouble-shooting program, which will be in place
prior to restart. This item is closed based upon this commitment.
B.
(Closed) Follow-up Item 86-06-06, HVAC Noise Level
This item was in regard to excess noise in the control room caused
by the operation of the control room emergency ventilation system.
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The' licensee' reduced the system supply. fan speed by 20%,. and opened
the system dampers.to maintain the original flow.' This change
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resulted in.a reduction in noise ~ level from approximately 66 DB to
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approximately 58 DB, which is well within the NUREG 0700
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recommendation of less than 65 DB.-
This item is' closed. This issue
was also identified. originally as RV-0-13 in report 86-07. RV-0-13
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remains open pending the inspection discussed in Paragraph 2.B
above.
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C.
(Closed) Unresolved Item 86-07-04', HVAC Availability
This unresolved item concerned the operability status for the "A"
and "B" trains of the control room Emergency Ventilation System.
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. during the December 26, 1985 event. During the event: the emergency
/entilation system was turned off because of high noise, the "B"
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crain.would not control automatically because it was inadvertently
disarmed by operators.who failed to recognize that the "B" train
could not be reset while a Safety Features Actuation signal was
still present, and the "A" train was enabled but would not come on
until temperature in the control room reached the design setpoint of
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80 degrees.
The licensee tested the system in accordance with test procedure STP
198-in May, 1986. .From this test, the licensee determined that the
system was operable during the event.
In this test, the licensee
confirmed, that the setpoint of the thermostat for the "B" train was
set at'75 degrees, and the "A" train was set at 80 degrees. The
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licensee has since changed the system design so that both systems
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operate to maintain 75 degrees.
Based on the licensee's testing and
evaluation, this item is closed.
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D.
(Closed) Unresolved Item 85-25-02, Broken RCP Capscrews
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This issue concerns the licensee's failure to generate a
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Nonconformance Report (NCR) for eleven of sixteen bearing cap screws.
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which were discovered broken (April 15,1985). The licensee was
working on the. pump (P-2108) to replace a leaking seal, and during
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this period decided to perform a Ten Year Inservice Inspection.
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During the ISI, these broken capscrews were discovered. The licensee
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and the Bingham-Willamette (BWC) representative who was onsite for-
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the maintenance and ISI work, contacted BWC in the corporate office,
and resolve this issue. The disposition was to increase the torque
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value of these capscrews to 40 foot-pounds (G. Parks, BWC to SMUD,
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April 23, 1985.
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The inspector's review of this issue identified that neither an NCR
or an Operational Deficiency Report (ODR) had been generated upon
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identification of the broken cap screws. After the inspector
identified this issue to the licensee, on September 4, 1985, the
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licensee generated an ODR (# 285). The RCS system and Reactor
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Coolant Pump are identified in the master equipment List as, Class 1,
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and as such, any nonconformances would require an NCR to be
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processed. The inspector expressed concern that, since the licensee
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had resolved and corrected the nonconformance so soon, the
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documentation process may have been circumvented.
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These circumstances become more significant in light of the
following events:
A licensee office memorandum to G. Coward from G. Clefton,
- dated September 5,1985, identified that: in August 1985, the
Oconee Nuclear Facility, which has identical Bingham-Willamette
-(BWC) pumps, discovered six of the same 16 capscrews with
their' heads broken off.
In addition to these broken 1.5 inch
cap screws, Oconee's pump had all.16 of 16 3.5 inch bearing
assembly capscrews with there heads broken off. On Drawing
J-256 of the pump, these 3.5 inch capscrews would be
.imediately to the right and up from the other 1.5 inch
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capscrews, and are identified as part # 37.3.
The inspector discussed the Rancho Seco and Oconee pump
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capscrew problems with Mr. Gordon Parks of BWC, in an effort to
clarify the significance of this issue. Oconee had identified
that, with the 3.5 inch capscrew heads broken off at the
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stem / head joint, the upper bearing support half could have
axial motion. The flow induced motion, created by the
recirculation impeller, allowed the loose heads to gouge the
stuffing box walls at Oconee and eroded the loose parts to a
size which allowed them to escape (into the small shaft
impeller imediately above the bearing halves).
Oconee increased the bearing assembly (part No. 37.3) torque,
capscrew bolt size and material strength. SMUD is obtaining
details from BWC for upgrade plans to the bearing assembly,
such as larger bolts of higher strength materials.
The inspector observed that these issues should be tracked or
dispositioned, within the licensee's system, on an NCR as per
licensee Quality Assurance Procedure 17, " Nonconforming
Material Control" Revision 4, which defines a Nonconformance as
"a deficiency in characteristic, documentation, or procedure
which renders the quality of an item unacceptable or
indeterminate."
QAP 17, Revision 1, effective March 20, 1985, which was in
effect at the time of the discovery of the broken cap screws,
states that:
" Systems, equipment and appurtenances,
components, parts, or material which do not meet the specified
requirements of purchase orders, design drawings,
operational / test documents, or construction documents shall be
considered nonconforming." This procedure goes on to define
" Repair" as: "A disposition which permits the reprocessing of
material or change to the system to bring it into an acceptable
condition (in this case, increased torquing of the capscrews
was decided upon with BWC, to prevent cycling fatigue),
although still departing from established requirements. This
disposition requires Engineering Review Board approval." This
procedure specifies that the Engineering Review Board must
approve all " Accept" or " Repair" dispositions of nonconforming
material or systems.
"The Board is composed of the managers of
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Quality Assurance, Nuclear Engineering, and Nuclear Operations
or their designated representatives...."
This procedure, QAP 17, goes on to say that: "When operational systems or
components are not performing their intended function or are not installed
in accordance with design specifications:
"A.
An NCR shall be initiated and processed unless it is determined
that the component, structure, or system can be returned to a
functional or operational status through rework or
replacement...."
"B.
A serialized work request shall be utilized to provide audit
capability whenever rework / replacement is required to return a
Class 1 system to functional or operational status if an NCR is
not initiated."
The inspector concluded that these two provisions did not apply in this
case since this disposition involved a change to the system torquing
requirements.
Therefore, this is an apparent violation (87-14-01).
4.
Control Room Emergency Ventilation System (RV-0-13, Open)
The inspector and two NRC contract personnel from Argonne National
Laboratories (ANL), " walked-down" the control room and technical support
center normal and emergency ventilation systems. This system inspection
was to determine if adequate test port locations were available for
determining system flows and balances.
In addition, this inspection was
a familiarization and inspection of the system construction and layout.
Currently, the ifcensee is finishing upgrades and modifications made
during this outage, and is scheduled to verify system performance by the
later part of April 1987. Many of the the licensee's system, maintenance
and surveillance procedures are in draft, awaiting final verification
during system testing. The NRC presently intends to confirm the
licensee's system performance, by a flow balance, once the system has
been declared operational by SMUD, and maintenance and surveillance
procedures are finialized. This issue previously identified as RV-0-13,
remains open pending completion of this NRC review.
During the system walkdown, the inspector identified silicone sealing
compound applied to the duct and components of the Emergency ventilation
system. The inspector informed the licensee that this is specifically
prohibited by Regulatory Guide 1.52, March 1978, Section 5 paragraph 4;
"The use of silicone sealants or any other temporary patching material on
filters, housing, mounting frames or ducts should not be allowed." The
licensee is comitted to this Guide, by Section 9.7.3.6 " Codes,
Standards, Tests", of the FSAR, Paragraph 4; "The essential air
filtration unit is designed and constructed in accordance with the
requirements of Regulatory Guide 1.52."
The use of silicone sealant is
an apparent Deviation to the licensee's comitments (87-14-02).
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5.
Follow-up of NUREG-0737 Issues
Item I.D.2.3 (0 pen) This item concerns upgrading of the Safety Parameter
Display System (SPDS).
NRR completed an audit of the SPDS, in October
1986, and identified many incomplete issues such as: . cluttered-
alphanumeric displays, adequacy of radiation data a*d adequacy of
isolation devices used to prevent electrical interference.
NRR.is
evaluating the licensee's schedule for responding to these issues.
A NRR inspection at Rancho Seco (April 7, 1987), identified that the
display format and radiation data issues have been resolved based on
licensee's commitments and a preliminary design review, but that the
software validation and qualification of electrical isolators are
critical path activities for the upgraded SPDS (Regulatory Guide 1.97
requirements) and NRR considers these issues a restraint to restart.
This item will remain open pending NRR's review and resolution of these
issues.
This item was previously reviewed in report 86-39.
Item'II.K.3 (0 pen) This item concerns the licensee's method of tripping
the Reactor Coolant Pumps during a loss of coolant accident.
The
licensee has obtained an extension to reply to this issue, which was due
December 31, 1986, until March 31, 1987.
This issue will be closed
following NRR's review and approval.
6.
Exit Interview
The inspection scope and findings were summarized on March 27, 1987, with
those persons indicated in paragraph 1 above.
The inspector described
the areas inspected and discussed in detail the inspection findings.
A
licensee representative acknowledged the inspectors findings.
The
following new items were identified during this inspection:
Violation 50-312/87-14-01
Deviation 50-312/87-13-02